OLED sub-pixel circuit architecture and related methods

Abstract

The present disclosure provides devices and methods thereof. The devices include a substrate. An inorganic layer is disposed on the substrate. The inorganic layer defines sub-pixels of the device. The inorganic layer includes a plurality of overhang structures. The device includes a first sub-pixel, including a first anode having a first thickness, where a first organic light emitting diode (OLED) material is disposed over the first anode. The device includes a second sub-pixel, including a second anode having a second thickness, where a second OLED material is disposed over the second anode. The device includes a third sub-pixel, including a third anode having a third thickness, where a third OLED material is disposed over the third anode. The first thickness is greater than the second thickness, and the first OLED material and the second OLED material are the same.

What is claimed is: 
     
       1. A device, comprising:
 a substrate; 
 an inorganic layer disposed on the substrate, the inorganic layer defining sub-pixels of the device, wherein the inorganic layer comprises a plurality of overhang structures defining overhangs; 
 a first sub-pixel comprising:
 a first anode having a first sub-layer, a second sub-layer, and a third sub-layer disposed over the substrate, the third sub-layer having a first thickness disposed over the substrate; 
 a first organic light-emitting diode (OLED) material disposed over and in direct contact with the third sub-layer of the first anode; and 
 a first encapsulation layer contacting a sidewall of the overhang structures under an overhang and an underside surface of the overhang structures of the first sub-pixel; 
 
 a second sub-pixel comprising:
 a second anode having a first sub-layer, a second sub-layer, and a third sub-layer disposed over the substrate, the third sub-layer having a second thickness disposed over the substrate; 
 a second OLED material disposed over and in direct contact with the third sub-layer of the second anode; and 
 the first encapsulation layer or a second encapsulation, the second encapsulation layer contacting the sidewall of the overhang structures under the overhangs and the underside surface of the overhang structures of the second sub-pixel; and 
 
 a third sub-pixel comprising:
 a third anode having a first sub-layer, a second sub-layer, and a third sub-layer disposed over the substrate, the third sub-layer having a third thickness disposed over the substrate; and 
 a third organic light-emitting diode (OLED) material disposed over and in direct contact with the third sub-layer of the third anode, wherein:
 the first thickness is greater than the second thickness, and 
 the first OLED material and the second OLED material are the same; and 
 
 a third encapsulation layer contacting the sidewall of the overhang structures under the overhangs and the underside surface of the overhang structures of the third sub-pixel, wherein the first encapsulation layer and the third encapsulation layer are separated from each other. 
 
 
     
     
       2. The device of  claim 1 , further comprising:
 a first color filter disposed over the first sub-pixel; 
 a second color filter disposed over the second sub-pixel; and 
 a third color filter disposed over the third sub-pixel. 
 
     
     
       3. The device of  claim 1 , wherein the second thickness is greater than the third thickness. 
     
     
       4. The device of  claim 1 , wherein the first OLED material, the second OLED material, and the third OLED material are the same. 
     
     
       5. The device of  claim 1 , further comprising a pixel defining layer (PDL) disposed on the substrate and below the inorganic layer. 
     
     
       6. The device of  claim 1 , wherein the first sub-pixel and the second sub-pixel share the first OLED material and the second OLED material. 
     
     
       7. The device of  claim 1 , further comprising a plurality of mask structures disposed over an encapsulation layer, the plurality of mask structures aligned with the plurality of overhang structures. 
     
     
       8. The device of  claim 7 , wherein a color filter is disposed between the plurality of mask structures. 
     
     
       9. The device of  claim 8 , further comprising a backing material disposed over the color filter and the plurality of mask structures. 
     
     
       10. The device of  claim 1 , wherein an intermediate layer is disposed on the first encapsulation layer and the third encapsulation layer and the intermediate layer is disposed in a gap between the first encapsulation layer and the third encapsulation layer. 
     
     
       11. A device, comprising:
 a substrate; 
 an inorganic layer disposed on the substrate, the inorganic layer defining sub-pixels of the device, wherein the inorganic layer comprises a plurality of overhang structures; 
 a first sub-pixel comprising:
 a first anode comprising a first sub-layer, a second sub-layer, and a third sub-layer disposed over the substrate, the third sub-layer having a first thickness disposed over the substrate; and 
 a first organic light-emitting diode (OLED) material disposed over and in direct contact with the third sub-layer of the first anode; 
 
 a second sub-pixel comprising:
 a second anode the first sub-layer, the second sub-layer, and the third sub-layer disposed over the substrate, the third sub-layer of the second anode having a second thickness disposed over the substrate; and 
 a second OLED material disposed over and in direct contact with the third sub-layer of the second anode; and 
 
 a third sub-pixel comprising:
 a third anode having a third thickness disposed over the substrate; and 
 a third organic light-emitting diode (OLED) material disposed over and in direct contact with the third sub-layer of the third anode; and 
 
 a global passivation layer disposed over the first sub-pixel, the second sub-pixel, the third sub-pixel, and the plurality of overhang structures; 
 wherein the first thickness of the third sub-layer of the first anode is greater than the second thickness of the third sub-layer of the second anode, and 
 wherein the first OLED material and the second OLED material are the same. 
 
     
     
       12. The device of  claim 11 , further comprising a pixel defining layer (PDL) disposed on the substrate and below the inorganic layer. 
     
     
       13. The device of  claim 11 , wherein the first sub-pixel and the second sub-pixel share the first OLED material and the second OLED material. 
     
     
       14. The device of  claim 11 , further comprising a plurality of mask structures disposed over the global passivation layer, wherein the plurality of mask structures aligned with the plurality of overhang structures, and wherein a color filter is disposed between the plurality of mask structures. 
     
     
       15. The device of  claim 14 , further comprising a backing material disposed over the color filter and the plurality of mask structures. 
     
     
       16. The device of  claim 11 , further comprising:
 a first color filter disposed over the first sub-pixel; 
 a second color filter disposed over the second sub-pixel; and 
 a third color filter disposed over the third sub-pixel. 
 
     
     
       17. The device of  claim 11 , wherein the second thickness is greater than the third thickness. 
     
     
       18. The device of  claim 11 , wherein the second thickness and the third thickness are the same. 
     
     
       19. The device of  claim 11 , wherein the first OLED material, the second OLED material, and the third OLED material are the same. 
     
     
       20. A device, comprising:
 a substrate; 
 an inorganic layer disposed on the substrate, the inorganic layer defining sub-pixels of the device, wherein the inorganic layer comprises a plurality of overhang structures; 
 a first sub-pixel comprising:
 a first anode comprising a first sub-layer, a second sub-layer, and a third sub-layer disposed over the substrate, the third sub-layer having a first thickness disposed over the substrate; and 
 a first organic light-emitting diode (OLED) material disposed over and in direct contact with the third sub-layer of the first anode; 
 
 a second sub-pixel comprising:
 a second anode, the first sub-layer, the second sub-layer, and the third sub-layer disposed over the substrate, the third sub-layer of the second anode having a second thickness disposed over the substrate; and 
 a second OLED material disposed over and in direct contact with the third sub-layer of the second anode; and 
 
 a third sub-pixel comprising:
 a third anode, the first sub-layer, the second sub-layer, and the third sub-layer disposed over the substrate, the third sub-layer of the second anode having a third thickness disposed over the substrate; and 
 a third organic light-emitting diode (OLED) material disposed over and in direct contact with the third sub-layer of the third anode, 
 
 wherein the first thickness of the third sub-layer of the first anode is greater than the second thickness of the third sub-layer of the second anode, 
 wherein the second thickness of the third sub-layer of the second anode is greater than the third thickness of the third sub-layer of the third anode, and 
 wherein the first OLED material and the second OLED material are the same. 
 
     
     
       21. The device of  claim 20 , further comprising a pixel defining layer (PDL) disposed on the substrate and below the inorganic layer. 
     
     
       22. The device of  claim 20 , wherein the first sub-pixel and the second sub-pixel share the first OLED material and the second OLED material. 
     
     
       23. The device of  claim 20 , further comprising a plurality of mask structures disposed over an encapsulation layer, the plurality of mask structures aligned with the plurality of overhang structures. 
     
     
       24. The device of  claim 23 , wherein a color filter is disposed between the plurality of mask structures. 
     
     
       25. The device of  claim 20 , further comprising:
 a first color filter disposed over the first sub-pixel; 
 a second color filter disposed over the second sub-pixel; and 
 a third color filter disposed over the third sub-pixel. 
 
     
     
       26. The device of  claim 20 , wherein the first OLED material, the second OLED material, and the third OLED material are the same. 
     
     
       27. A device, comprising:
 a substrate; 
 an inorganic layer disposed on the substrate, the inorganic layer defining sub-pixels of the device, wherein the inorganic layer comprises a plurality of overhang structures defining overhangs; 
 a plurality of sub-pixels, each sub-pixel comprising:
 an anode comprising:
 a first sub-layer; 
 a second sub-layer disposed over the first sub-layer; and 
 a third sub-layer disposed over the second sub-layer; 
 
 an organic light-emitting diode (OLED) material disposed over and in direct contact with the third sub-layer of the anode, the OLED material comprising:
 a first emission material; 
 a charge generation layer; and 
 a second emission material; 
 
 a cathode disposed over and in direct contact with the OLED material; 
 an encapsulation layer disposed over the OLED material, the encapsulation layer contacting a sidewall of the overhang structures under the overhangs and an underside surface of the overhang structures; 
 an intermediate layer is disposed on the first encapsulation layer; and 
 a color filter disposed over the intermediate layer; 
 
 wherein the device comprises at least a first anode comprising a first thickness, a second anode comprising a second thickness, and a third anode comprising a third thickness. 
 
     
     
       28. The device of  claim 27 , wherein the first thickness, the second thickness and the third thickness are the same. 
     
     
       29. The device of  claim 27 , wherein the first thickness, the second thickness and the third thickness are different. 
     
     
       30. The device of  claim 27 , wherein encapsulation layers of a first sub-pixel, a second sub-pixel, and a third sub-pixel are separated from each other and the intermediate layer is disposed in gaps between the encapsulation layers.